Dual Interface Separable Insulated Connector with Overmolded Faraday Cage

ABSTRACT

A dual interface separable insulated connector comprising a faraday cage molded over a bus bar for use in an electric power system and a method of manufacturing the same are provided. The faraday cage can be disposed within a semi-conductive shell. The configuration of the separable insulated connector can provide for easier bonding between the faraday cage and insulating material. Additionally, the configuration can eliminate or reduce the need to coat the bus bar with an adhesive agent and to smooth the metal bus bar to remove burrs, other irregularities, and sharp corners from the bar. Manufacturing the dual interface separable insulated connector can include molding a semi-conductive rubber faraday cage over a conductive bus bar, inserting the faraday cage into a shell, and injecting insulating material between the faraday cage and shell.

RELATED PATENT APPLICATIONS

This patent application is a continuation of U.S. patent applicationSer. No. 12/072,164, entitled “Dual Interface Separable InsulatedConnector With Overmolded Faraday Cage,” filed Feb. 25, 2008, which isrelated to co-pending U.S. patent application Ser. No. 12/072,498,entitled “Separable Connector with Reduced Surface Contact,” filed Feb.25, 2008; U.S. patent application Ser. No. 12/072,513, entitled“Push-Then-Pull Operation Of A Separable Connector System,” filed Feb.25, 2008; U.S. patent application Ser. No. 12/072,333, entitled“Separable Connector With Interface Undercut,” filed Feb. 25, 2008; andU.S. patent application Ser. No. 12/072,193, entitled “Method OfManufacturing A Dual Interface Separable Insulated Connector WithOvermolded Faraday Cage,” filed Feb. 25, 2008. The complete disclosureof each of the foregoing related applications is hereby fullyincorporated herein by reference.

TECHNICAL FIELD

The invention relates generally to separable insulated connector systemsfor electric power systems. More specifically, the invention relates toa separable insulated connector having a molded faraday cage.

BACKGROUND

Separable insulated connectors provide an electric connection betweencomponents of an electric power system. More specifically, separableinsulated connectors often connect sources of energy—such as cablescarrying electricity generated by a power plant—to energy distributionsystems or components thereof, such as switchgears and transformers.Other types of separable insulated connectors can connect to otherseparable insulated connectors on one or both of their ends.

Depending on the type and function of a separable insulated connector,the connector can include a variety of different interfaces. Forexample, many separable insulated connectors include two interfaces, oneat each end of the connector. Some separable insulated connectors caninclude one male interface and one female interface, two maleinterfaces, or two female interfaces.

An exemplary connector with two female interfaces can, for example,include a bus bar—or conductive member that carries current—connectingthe two female interfaces. Each female interface can include a “cup”through which one end of a probe can be inserted and then connected tothe bus bar disposed within the separable insulated connector. The otherend of the probe then can be connected to energy distribution componentsor other separable insulated connectors.

The cups are typically made from semi-conductive material and thus canserve as a faraday cage. As used throughout this application, a“semi-conductive” material can refer to rubber or any other type ofmaterial that carries current, and thus can include conductivematerials. The purpose of a faraday cage is to shield all gaps of airwithin the mating components of the separable insulated connector, asthese air gaps can cause corona discharge within the connector. Thisdischarge can occur if there is a voltage drop across the air gaps, andthe discharge can corrode the rubber materials often used to make theseparable insulated connector. The faraday cage ensures that the variousmating components have the same electric potential, and thus preventscorona discharge within the mating components.

Conventionally, the cups of such female-female separable insulatedconnectors are made from a rigid, conductive metal, such as copper. Thecups, as well as the bus bar connecting them, are placed within asemi-conductive shell of the separable insulated connector. Conventionalseparable insulated connectors also can include various layers ofinsulating material—such as between the cups and the probes insertedtherein, between the cups and the shell, and around the bus bar. Thevarious layers of insulating material used in conventional separableinsulated connectors can provide a barrier to shield the high voltagecomponents from the exposed shell. Such a configuration can reduce orremove the risk of electric shock from touching the exterior of theseparable insulated connectors.

This configuration of conventional separable insulated connectors hascreated several problems. Notably, it is difficult to bond theinsulating material—which is generally made from a rubber such asethylene propylene dienemonomer (EPDM) rubber, thermoplastic rubbers(TPRs), and/or silicone rubber—to the cups or the bus bar, both of whichare generally made from metal. Rubber does not typically form a strongbond with metal. A strong bond between the insulating material and themetal cups and/or bus bar also is desirable because without a strongbond, air gaps can form between the metal and insulating materials.Corona or partial discharge can occur within the air gaps between theconductive metal and the semi-conductive rubber. The discharge can leadto severe damage of the insulating material and the connector.Manufacturers of conventional separable insulated connectors often coatthe bus bar and/or cups with an adhesive to enhance the bond with theinsulating material. However, in addition to creating an expensive extrastep in the manufacturing process, these adhesives can be toxic and cancause environmental problems during storage, manufacturing, anddisposal.

An additional problem created by the conventional configuration of suchseparable insulated connectors also stems from having insulatingmaterial bordering the bus bar. In such a configuration, the surfaces,edges, and corners of the bus bar must be smoothed and/or softened toremove any burrs, other irregularities, or sharp corners that may bepresent on the bar. Absent this step, such items on the bus bar cancause stress to or otherwise damage the insulating material thatsurrounds the bus bar, given the difference in electric potentialbetween the bus bar and the insulating material, thereby causing damageto the entire separable insulated connector. Thus, manufacturers ofconventional bus bars must perform the time consuming, labor-intensive,and expensive process of smoothing the bus bars prior to applying theinsulating material.

Yet another problem with conventional separable insulated connectors isthe tendency for conventional faraday cages to disconnect from the busbar. The connection between conventional faraday cages and bus bars canbecome loosened during the manufacturing process, especially wheninsulating material is injected or otherwise inserted between thefaraday cage and the shell. If the connection between the bus bar andthe faraday cage is dropped, the faraday cage may no longer have thesame electric potential as the bus bar, which therefore defeats thepurpose of the faraday cage.

Thus, a need in the art exists for a separable insulated connector in anelectric power system that addresses the disadvantages found in theprior art. Specifically, a need in the art exists for a dual interfaceseparable insulated connector that does not require insulating materialto bond to the bus bar. A need in the art also exists for a dualinterface separable insulated connector with a faraday cage that canbond to insulating material without the use of an adhesive material, ifdesired. Yet another need in the art exists for a dual interfaceseparable insulated connector with a faraday cage—and a method ofmanufacturing the same—where the connection between the faraday cage andbus bar is stronger and less likely to disconnect.

SUMMARY

The invention provides a dual interface separable insulated connectorfor use in an electric power system that includes a faraday cage thatcan bond to insulating material without the use of adhesive material.The invention also provides a dual interface separable insulatedconnector that can prevent the need to bond insulating material directlyto a bus bar disposed therein. Specifically, the invention provides aseparable insulated connector with a dual interface faraday cage madefrom a semi-conductive rubber material that can be molded over a bus barproviding a connection between conductive members inserted into the twointerfaces of the faraday cage.

In one aspect, the invention provides a rubber faraday cage thatovermolds a bus bar. The faraday cage can be made from a variety ofdifferent materials, including ethylene propylene dienemonomer (EPDM)rubber, thermoplastic rubbers (TPRs), and silicone rubber. The rubberused in manufacturing the faraday cage can be mixed with a conductivematerial, such as carbon black, thereby causing the faraday cage to besemi-conductive. Other suitable semi-conductive materials known to thosehaving ordinary skill in the art and having the benefit of the presentdisclosure can be used instead of a semi-conductive rubber.

The faraday cage can include two interfaces for connecting to twoprobes. The probes then can be connected to other separable insulatedconnectors, switchgear, transformers, or other energy distributioncomponents. A conductive member, such as a bus bar, can provide anelectrical connection between the two probes inserted into the faradaycage, as is the practice with certain conventional separable insulatedconnectors utilizing faraday cages.

Unlike with conventional separable insulated connectors, however, thefaraday cage can be molded over the bus bar, thereby avoiding many ofthe problems and difficulties associated with the prior art. Molding thesemi-conductive faraday cage over the bus bar can eliminate the need forinsulating material to bond to the metal bus bar. Instead, thesemi-conductive material of the faraday cage can surround the bus bar,and then insulating material can bond to the semi-conductive material.

In such a configuration, the bus bar need not be smoothed or finished toremove burrs, other irregularities, or sharp corners. Because the busbar can be bordered by a semi-conductive rubber faraday cage, the rubberfaraday cage can have the same or similar electric potential as the busbar, and thus any burrs present on the bar may not cause stress ordamage to the rubber faraday cage. Furthermore, the surface of therubber faraday cage can be smoothed much more easily than the metal busbar before insulating material will be applied to the faraday cage.Thus, in such a configuration, the insulating material can contact asmooth, semi-conductive surface (i.e., the faraday cage) without themanufacturer having to engage in the lengthy and costly procedure ofsmoothing the metal bus bar.

Another advantage associated with eliminating the need for an insulatingmaterial to bond to the bus bar is the reduction or removal of the needto apply an adhesive agent to the bus bar. The rubber insulatingmaterial can bond to the rubber faraday cage much more easily than withthe metal bus bar. For example, if the insulating material is applied tothe faraday cage in a liquid state, bonding of the insulating materialto the faraday cage can occur upon curing of the insulating material.Thus, a strong, tight bond (i.e., without air gaps) can be formedbetween the rubber faraday cage and the rubber insulating materialwithout the use of a costly and potentially toxic adhesive agent.Although air gaps may exist between the bus bar and the faraday cage dueto the comparatively poor bonding ability of rubber to metal, these airgaps do not pose a problem to the separable insulated connector becausethe faraday cage and bus bar have the same electric potential.

In another aspect, the invention provides a dual interface separableinsulated connector that includes a semi-conductive outer shell with afaraday cage disposed therein, the faraday cage having two interfaces.As described previously, the faraday cage—including each of the twointerfaces—can be made from a semi-conductive rubber material, such asEPDM, TPR, or silicone mixed with a conductive material such as carbonblack.

The shell of the separable insulated connector can be made from the samematerial as the faraday cage. For example, the shell also can be madefrom a semi-conductive rubber material, such as EPDM, TPR, or siliconemixed with a conductive material such as carbon black. The separableinsulated connector also can include an insulating layer, as describedpreviously, between the faraday cage and the shell.

The use of a semi-conductive material to form the interfaces or “cups”can eliminate the need to use an adhesive agent in bonding insulatingmaterial to the faraday cage interfaces. Because the faradaycage—including the interfaces—can be made from a rubber material ratherthan a metal such as copper, the insulating material can bond to theinterfaces much more easily, as described previously with respect to thebus bar. The use of a semi-conductive material to form the faraday cageinterfaces allows the faraday cage to maintain the ability—associatedwith conventional faraday cages—to prevent corona discharge.

The interfaces of the dual interface separable insulated connector canbe configured such that a probe can be inserted into each of theinterfaces. When combined with a bus bar providing an electricconnection between the two interfaces, the dual interface separableinsulated connector can provide an electric connection between the twoprobes inserted therein. Thus, upon connection of the two probes to afirst energy distribution component and second energy distributioncomponent, respectively, the separable insulated connector can providean electric connection between the two energy distribution components.

In yet another aspect, the invention provides a method of manufacturinga dual interface separable insulated connector that includes asemi-conductive outer shell with a faraday cage disposed therein. Amanufacturer can inject a semi-conductive rubber material into a mold orpress to form the semi-conductive shell. The shell then can be curedand/or hardened.

Then, the manufacturer can take a conductive member or bus bar and putit into a mold or press in the shape of the dual interface faraday cage.Two steel mandrels also can be inserted into the mold to provide theholes or openings that will form the two interfaces of the faraday cage.The manufacturer then can inject a semi-conductive rubber material intothe mold to form the faraday cage. The faraday cage—with the bus barbeing disposed therein—then can be cured and/or hardened.

The faraday cage then can be inserted into the shell. To fit the faradaycage into the shell, the shell may need to be cut or split, manufacturedto include such a cut or split therein, or formed into two separatepieces during the molding process. Once the faraday cage has beeninserted into the shell, the shell can be made (or remade) into onepiece. Then, insulating material can be injected into the shell, therebyproviding a layer of insulating material between the faraday cage andthe shell. The insulating material then can be cured and/or hardened,thereby securing the faraday cage within the shell.

These and other aspects, objects, features, and embodiments of theinvention will become apparent to a person of ordinary skill in the artupon consideration of the following detailed description of illustrativeembodiments, which include the best mode for carrying out the inventionas presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional side view of a dual interface separableinsulated connector comprising a faraday cage molded over a bus bar,according to an exemplary embodiment.

FIG. 2 is a diagram illustrating an electric power system utilizing adual interface separable insulated connector comprising a faraday cagemolded over a bus bar, according to an exemplary embodiment.

FIG. 3 is a flow diagram illustrating an exemplary method formanufacturing a dual interface separable insulated connector comprisinga faraday cage molded over a bus bar.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following description of exemplary embodiments refers to theattached drawings, in which like numerals indicate like elementsthroughout the figures.

FIG. 1 is a cross-sectional side view of a dual interface separableinsulated connector 100 comprising a faraday cage 102 molded over a busbar 106, according to an exemplary embodiment. The dual interfaceconnector 100 includes a shell 104, a faraday cage 102 disposed therein,and a bus bar 106 disposed within the faraday cage 102. In theillustrated embodiment, the dual interface connector 100 includes afirst opening 112A and second opening 112B, and probes 110A, 110B isinserted into each of the first and second openings 112A, 1121B,respectively. In an exemplary embodiment, the faraday cage 102 caninclude a first cup 108A and a second cup 108B, corresponding with theshell's 104 first and second openings 112A, 112B, respectively. Inanother an exemplary embodiment, the first and second probes 110A, 110Bcan be inserted through the first and second openings 112A, 112B andthrough the first and second cups 108A, 108B, and then attached to thebus bar 106, thereby providing a connection from the first probe 110A tothe second probe 110B. In another exemplary embodiment, the dualinterface connector 100 also can include a layer 114 of insulatingmaterial between the faraday cage 102 and the shell 104. As shown inFIG. 1, in exemplary embodiments, both the shell 104 and the faradaycage 102 disposed therein can have a substantially “U” shape.

The shell 104 of the dual interface connector 100 can be made from avariety of materials. In exemplary embodiments, the shell 104 can bemade from semi-conductive rubber. Examples of suitable rubbers includeethylene propylene dienemonomer (EPDM) rubber, thermoplastic rubbers(TPRs), and silicone rubber. Any of these rubbers then can be mixed witha conductive material, such as carbon black or other suitable material,thereby providing the semi-conductive property for the shell 104.

Similarly, the faraday cage 102 of the dual interface connector 100 canbe made from a variety of materials. In an exemplary embodiment, thefaraday cage 102 can be made from the same material used to make theshell 104. For example, the faraday cage 102 can be made fromsemi-conductive rubber, such as a mixture of a conductive material andEPDM rubber, TPRs, or silicone rubber.

The layer 114 of insulating material between the shell 104 and thefaraday cage 102 also can be made from a variety of materials. Invarious exemplary embodiments, the insulating material can be made fromany suitable non-conductive material, known to those having ordinaryskill in the art and having the benefit of the present disclosure. Inparticular exemplary embodiments, the insulating material can be madefrom EPDM rubber, TPRs, or silicone rubber, but without being mixed witha significant amount of conductive material, thereby retaining aninsulating property.

In an exemplary embodiment, the dual interface connector 100 also caninclude other insulating layers. For example, the faraday cage 102 caninclude an additional insulating layer 116A, 116B on the first andsecond cups 108A, 108B inside the faraday cage 102. In one embodiment,these cup insulating layers 116A, 116B can be made from the samematerial used in the insulating layer 114 between the shell 104 andfaraday cage 102. In an alternative exemplary embodiment, the cupinsulating layers 116A, 116B can be made from a different insulatingmaterial. Particular exemplary types of insulating materials that can beused to form the cup insulating layers 116A, 116B are disclosed in U.S.Pat. No. 5,655,921 to Makal et al., the complete disclosure of which ishereby fully incorporated herein by reference. As shown in FIG. 1, thecup insulating layers 116A, 116B can be relatively thin when compared tothe insulating layer 114 between the shell 104 and faraday cage 102.

In other exemplary embodiments, the shell 104 of the dual interfaceconnector 100 also can include additional insulating layers. Forexample, as shown in FIG. 1, the shell 104 can include two insulatingsleeves 118A, 118B, each one located near the first and second openings112A, 112B of the shell 104. As with the cup insulating layers 116A,116B described previously, the insulating sleeves 118A, 118B can be madefrom the same material used in the insulating layer 114 between theshell 104 and faraday cage 102, or alternatively, from a differentsuitable material.

In exemplary embodiments, the additional insulating layers such as thecup insulating layers 116A, 116B and the insulating sleeves 118A, 118Bcan provide additional insulation for the dual interface connector 100.The cup insulating layers 116A, 116B can provide load-break switchingfor the dual interface connector 100. Additionally, the cup insulatinglayers 116A, 116B can protect against partial vacuum flashover whichcould cause the connector 100 to be pulled off of a bushing connectedthereto. The insulating sleeves 118A, 118B can prevent a switchingfailure made when separating a probe 110A, 110B from the connector 100.Absent the insulating sleeves 118A, 118B, a probe 110A, 110B may contactthe semi-conductive shell 104, thereby causing a switching failure.

In various exemplary embodiments, the shell 104 of the dual interfaceconnector 100 also can comprise a variety of additional components. Forexample, as shown in FIG. 1, the shell 104 of the dual interfaceconnector 100 also can include a pulling eye 122. The pulling eye 122can function as a handle for the dual interface connector 100. Thepulling eye 122 can be pulled or pushed to install the dual interfaceconnector 100 on an energy distribution component, to adjust theposition of the dual interface connector 100, or to disconnect the dualinterface connector 100 from an energy distribution component. In oneexemplary embodiment, the pulling eye 122 can be made from the samematerial used to make the shell 104, such as EPDM rubber or another typeof rubber. In a particular exemplary embodiment, the pulling eye 122 caninclude a steel insert 122 b, disposed within the rubber, providingstrength and resilience to the pulling eye 122.

In another exemplary embodiment, the shell 104 of the dual interfaceconnector 100 also can include an injection port 120, through whichinsulating material can be injected. In yet another exemplaryembodiment, the shell 104 can include one or more ground wire tabs 124to which a wire can be attached and grounded. Because the shell 104 canbe made from semi-conductive rubber, the ground wire can provide groundshield continuity for the dual interface connector 100, therebyproviding deadfront safety for the shell 104. In other words, thegrounded shell 104 can allow operators to touch the exterior of the dualinterface connector 100 safely, thereby removing or reducing the risk ofaccidental electric shock.

In an exemplary embodiment, the first and second probes 110A, 110B canbe made from a variety of conductive materials, such as conductivemetals known to those having ordinary skill in the art and having thebenefit of the present disclosure. In one exemplary embodiment, theprobes 110A, 110B can be made from conductive copper. In a particularexemplary embodiment, the probes 110A, 110B can include a threaded end126A, 126B for connection to the bus bar 106.

The bus bar 106 can be made from a variety of conductive materials, suchas conductive copper or other metals. Regardless of the particularmaterial used, the bus bar 106 can include two holes 106A, 106B, intowhich the first and second probes 110A, 110B can be inserted andaffixed. In a particular exemplary embodiment, the threaded ends 126A,126B of the probes 110A, 110B can be screwed into corresponding threadsin the holes 106 a, 106 b of the bus bar 106. The conductive property ofthe bus bar 106 can carry load current, and thus can provide an electricconnection between the first and second probes 110A, 110B.

In an exemplary embodiment, the faraday cage 102 can be molded over thebus bar 106, such that entire bus bar 106 is disposed within the faradaycage 102. Because the bus bar 106 can be overmolded with the faradaycage 102, the bus bar 106 need not be polished, refined, or smoothed toremove any burrs on the bus bar 106. Instead, in an exemplaryembodiment, the rubber faraday cage 102 can be molded into a smooth,curved shape, which can take less effort than removing burrs from ametal bus bar 106.

Additionally, because the faraday cage 102 can be made from asemi-conductive material, it can have the same or similar electricpotential as the bus bar 106. Therefore, any air gaps that may bepresent between the faraday cage 102 and the bus bar 106 may not causecorona discharge.

In an exemplary embodiment, as described previously, and as shown inFIG. 1, the insulating layer 114 can border the faraday cage 102. Thebond between the faraday cage 102 and the insulating layer 114 can betighter than the bond between the faraday cage 102 and the bus bar 106.In other words, there may few air gaps, if any, between the faraday cage102 and the insulating layer 114, which can reduce or eliminate thepossibility of corona discharge between two layers 102, 114 having adifferent electric potential. In exemplary embodiments, such a tightbond can be formed relatively easily because both the faraday cage 102and the insulating layer 114 can be primarily made of rubber materialsthat bond to each other easily.

In another exemplary embodiment, as shown in FIG. 1, the first andsecond cups 108A, 108B of the faraday cage 102 can contact theinsulating layer 114 on the outer side of the cups 108A, 108B. Unlikewith conventional cup-shaped faraday cages that can be made fromconductive metal, the first and second cups 108A, 108B of the faradaycage 102 also can bond easily with the insulating material because thecups and the insulating material can be made from rubber.

In another exemplary embodiment, the inner side of the cups 108A, 108Bcan contact the cup insulating layers 116A, 116B, as describedpreviously. In yet another exemplary embodiment, an empty space 128A,128B can exist in the area inside the cup insulating layers 116A, 116B.These empty spaces 128A, 128B can be configured such that bushingscapable of interfacing with the probes 110A, 110B can be inserted andsecured therein. In a particular exemplary embodiment, such bushings canbe part of—or can be connected to—another separable insulated connectoror an energy distribution component.

The faraday cage 102 comprises the cups 108A, 108B and the portions thatextend around the bus bar 106.

FIG. 2 is a diagram illustrating an electric power system 200 utilizinga dual interface separable insulated connector 100 that comprises afaraday cage 102 molded over a bus bar 106, according to an exemplaryembodiment. In an exemplary embodiment, one end 126A of a first probe110A can be inserted into the first opening 112A of the dual interfaceseparable insulated connector 100, the first cup 108A, and the firsthole 106A of the bus bar 106, and the other end 226A of the first probe110A can be inserted into a bushing 230 that connects to anotherseparable insulated connector such as a T-body connector 232.Additionally, one end 126B of a second probe 110B can be inserted intothe second opening 112B of the dual interface separable insulatedconnector 100, the second cup 108B, and the second hole 106B of the busbar 106, and the other end 226B of the second probe 110B can be insertedinto an energy distribution component 234. In such an embodiment, thedual interface separable insulated connector 100 can provide an electricconnection between the T-body connector 232 and the energy distributioncomponent 234.

In an alternative embodiment, the dual interface separable insulatedconnector 100 can connect to the other separable insulated connectorwithout first connecting to a bushing 230 as shown in FIG. 2. In anotheralternative embodiment, the dual interface separable insulated connector100 can connect two separable insulated connectors together, rather thanconnecting to an energy distribution component 234. The dual interfaceseparable insulated connector 100 can connect to a variety of otherseparable insulated connectors and/or energy distribution components 234using a variety of configurations, known to those having ordinary skillin the art and having the benefit of the present disclosure.

FIG. 3 is a flow diagram illustrating a method 300 for manufacturing adual interface separable insulated connector 100 comprising a faradaycage 102 molded over a bus bar 106 according to an exemplary embodiment.The method 300 will be described with reference to FIGS. 1 and 3.

In step 305, liquid semi-conductive rubber is injected into a mold forthe shell 104 and then cured until the rubber has cured or solidified.Any of the various exemplary semi-conductive rubbers describedpreviously, such as EPDM rubber, TPRs, or silicone rubber can be used.

In an exemplary embodiment, the size, shape, dimension, andconfiguration of the mold can be selected based upon the desired size,shape, dimension, and configuration of the shell 104 of the dualinterface separable insulated connector 100. In another exemplaryembodiment, the mold can be shaped to include one or more ground wiretabs 124 and/or a pulling eye 122. Additionally, if the mold is shapedto include a pulling eye 122 on the shell 104, a metal insert can beplaced in the mold, approximately the size and shape of the pulling eye122, such that the insert can be disposed within the pulling eye 122. Asdescribed previously, the insert can provide additional strength for thepulling eye 122.

In step 310, a first set of steel mandrels is placed into a mold for thefaraday cage 102. In an exemplary embodiment, two steel mandrels can beplaced into the mold for the faraday cage 102, and can have a sizecorresponding with the first and second cups 108A, 108B. In anotherexemplary embodiment, the width of the first set of steel mandrels canbe wider than the desired width for the first and second cups 108A,108B, to account for the cup insulating layers 116A, 116B that may beformed. The first set of steel mandrels can be inserted into the holes106A, 106B of the bus bar 106. For example, the first set of steelmandrels can be screwed into the threads in the holes 106A, 106B of thebus bar 106. Additionally, as described previously with respect to theshell 104, the dimensions of the mold can be selected based upon thedesired dimensions of the faraday cage 102.

In step 315, the bus bar 106 is placed into the mold for the faradaycage 102 of the dual interface separable insulated connector 100.Optionally, the bus bar 106 can be coated with an adhesive agent.Although an adhesive agent may not be necessary, as the bond between thebus bar 106 and the faraday cage 102 can include air gaps as describedpreviously, an adhesive agent may be utilized if a stronger bond isdesired. Such a bond may be desired to prevent any warping or tearing ofthe faraday cage 102, insulating material, or shell 104 upon adjustingof the dual interface separable insulated connector 100, such as bypulling on the pulling eye 122.

In another exemplary embodiment, first and second holes 106A, 106B canbe created in the bus bar 106, such that first and second probes 110A,110B can be inserted and attached therein. In another exemplaryembodiment, the holes 106A, 106B can be threaded so as to correspondwith threaded ends 126A, 126B of the first and second probes 110A, 110B.

In step 320, liquid semi-conductive rubber is injected into the mold forthe faraday cage 102. Any of the various exemplary semi-conductiverubbers described previously, such as EPDM rubber, TPRs, or siliconerubber can be used. The semi-conductive rubber then can be cured untilit has cured and hardened.

In step 325, the faraday cage 102 is removed from the mold for thefaraday cage 102.

In step 330, the first set of steel mandrels is replaced with a secondset of steel mandrels. In an exemplary embodiment, the second set ofsteel mandrels are narrower than the first set. In another exemplaryembodiment, the second set of steel mandrels can have a widthsubstantially equal to the desired width of the first and second cups108A, 108B. The second set of steel mandrels can be inserted into theholes 106A, 106B of the bus bar 106. For example, the second set ofsteel mandrels can be screwed into the threads in the holes 106A, 106Bof the bus bar 106. In an alternative embodiment, a second set of steelmandrels might not be used, and instead, the hole created by the removalof the first set of steel mandrels may be left open for the remainder ofthe manufacturing process. For example, if the faraday cage 102 will notinclude cup insulating layers 116A, 116B, then a second set of steelmandrels may not need to be inserted into the faraday cage 102 afterremoval of the first set of steel mandrels.

In step 335, the faraday cage 102 is placed into a second mold. Thesecond mold for the faraday cage 102 can be larger in dimension than thefirst mold, and can be configured to form the cup insulating layers116A, 116B of the faraday cage 102 upon the injection of insulatingmaterial into the second mold.

In step 340, liquid insulating material is injected into the second moldto insulate the faraday cage 102 and then cured to form the cupinsulating layers 116A, 116B. As described previously, a variety ofrubber materials—such as EPDM rubber, TPRs, or silicone rubber—can beused to form the cup insulating layers 116A, 116B. The insulatingmaterial then can be cured until it has cured and hardened.

In step 345, the faraday cage 102 is removed from the second mold, andthe second set of steel mandrels is removed from the faraday cage 102.

In step 350, the faraday cage 102 is inserted into the shell 104. In anexemplary embodiment, the shell 104 can be cut or split—oralternatively, the shell 104 could have been formed in step 305 toinclude a cut or split therein—to provide additional flexibility suchthat the faraday cage 102 can be inserted therein. In an alternativeexemplary embodiment, the shell 104, when formed in step 305, can beformed in two separate pieces, thereby providing additional flexibilityand a larger opening into which the faraday cage 102 can be inserted.After the faraday cage 102 has been inserted into the shell 104, thesplits or pieces of the shell 104 can be attached (or reattached)together, thereby enclosing the faraday cage 102 within the shell 104.

In step 355, the insulating sleeves 118A, 1118B are formed and bonded tothe shell 104 of the dual interface separable insulated connector 100.In an exemplary embodiment, the insulating sleeves 118A, 118B can beformed by injecting suitable insulating material into a mold for theinsulating sleeves 118A, 118B. In another exemplary embodiment, theinsulating sleeves 118A, 118B then can be bonded to the shell 104 of thedual interface separable insulated connector 100 by using an adhesive.Alternatively, the insulating sleeves 118A, 118B can be attached to theshell 104 before the insulating sleeves 118A, 118B has completely cured,and thus it can bond to the shell 104 upon curing of the insulatingsleeves 118A, 118B.

In step 360, a third set of steel mandrels is inserted into the faradaycage 102. This third set replaces the second set of steel mandrelsremoved in step 345. In an exemplary embodiment, the third set of steelmandrels can be more narrow than the second set. In an alternativeembodiment, instead of replacing the second set of steel mandrels, thehole created by the removal of the steel mandrels may be left open forthe remainder of the manufacturing process. In an exemplary embodiment,if a third set of steel mandrels replaced the second set of steelmandrels, then the faraday cage 102 can be inserted into the shell 104with the third set of steel mandrels inserted therein. In variousexemplary embodiments utilizing a third set of steel mandrels, the thirdset of steel mandrels can be inserted into the faraday cage 102 atdifferent stages of the manufacturing process. For example, the thirdset of steel mandrels can be inserted into the faraday cage 102 duringor after steps 345, 350, or 355, or at any other time during themanufacturing process.

In step 365, the shell 104 and faraday cage 102 are placed into a thirdmold. In an exemplary embodiment, the third mold can be configured toform the insulating layer 114 upon injection of insulating material intothe third mold.

In step 370, insulating material is injected into the shell 104 and thencured. In an exemplary embodiment, the insulating material injected instep 345 can form the insulating layer 114 between the shell 104 andfaraday cage 102. In another exemplary embodiment, the insulatingmaterial can be injected through the injection port 120. In a particularembodiment, the injection port 120 can be opened before injection andclosed thereafter. As described previously, a variety of rubbermaterials—such as EPDM rubber, TPRs, or silicone rubber—can be used toform the insulating layer 114. The insulating material then can be cureduntil it has cured and hardened.

In an exemplary embodiment, the third set of steel mandrels (if present)in the faraday cage 102 can be removed from the faraday cage 102. In anexemplary embodiment, the first and second probes 110A, 110B can beinserted into the first and second holes in the bus bar 106 after thethird set of steel mandrels has been removed from the faraday cage 102.At this point, the dual interface separable insulated connector 100 canhave substantially the same form as the exemplary dual interfaceseparable insulated connector 100 shown in FIG. 1.

Many other modifications, features, and embodiments will become evidentto a person of ordinary skill in the art having the benefit of thepresent disclosure. It should be appreciated, therefore, that manyaspects of the invention were described above by way of example only andare not intended as required or essential elements of the inventionunless explicitly stated otherwise. It should also be understood thatthe invention is not restricted to the illustrated embodiments and thatvarious modifications can be made within the spirit and scope of thefollowing claims.

1. A faraday cage for a separable insulated connector, comprising: asemi-conductive rubber housing; and a conductive bus bar in contact withthe semi-conductive rubber housing; wherein the conductive bus bar isentirely disposed within the semi-conductive rubber housing.
 2. Thefaraday cage of claim 1, wherein the rubber housing comprises a mixturecomprising ethylene propylene dienemonomer rubber and a conductivematerial.
 3. The faraday cage of claim 1, further comprising: a firstcup defined by the rubber housing and disposed on the bus bar; and asecond cup defined by the rubber housing and disposed on the bus bar. 4.The faraday cage of claim 3, wherein the bus bar comprises a first holeand a second hole, wherein the first hole is aligned with the first cupand is configured to secure a first probe inserted therein, and whereinthe second hole is aligned with the second cup is configured to secure asecond probe inserted therein.
 5. The faraday cage of claim 3, furthercomprising: a first cup insulating layer disposed within the first cup;and a second cup insulating layer disposed within the second cup.
 6. Thefaraday cage of claim 1, wherein the bus bar comprises: a first hole;and a second hole, and wherein the faraday cage further comprises: afirst probe inserted into the first hole; and a second probe insertedinto the second hole, wherein an electrical connection exists betweenthe first probe and the second probe.
 7. The faraday cage of claim 6,wherein the bus bar provides the electrical connection between the firstprobe and the second probe.
 8. The faraday cage of claim 1, wherein thefaraday cage is disposed within a separable insulated connector.
 9. Thefaraday cage of claim 1, wherein the separable insulated connectorcomprises a dual interface separable insulated connector.
 10. Aseparable insulated connector, comprising: a shell; a faraday cagedisposed within the shell; and a conductive bus bar entirely disposedwithin the faraday cage, wherein the faraday cage comprises asemi-conductive rubber housing.
 11. The separable insulated connector ofclaim 10, wherein the shell comprises semi-conductive rubber.
 12. Theseparable insulated connector of claim 10, wherein the shell comprises amixture comprising ethylene propylene dienemonomer rubber and aconductive material.
 13. The separable insulated connector of claim 10,further comprising an insulating layer between the shell and the faradaycage.
 14. The separable insulated connector of claim 13, wherein theinsulating layer comprises rubber.
 15. The separable insulated connectorof claim 13, wherein the insulating layer comprises ethylene propylenedienemonomer rubber.
 16. The separable insulated connector of claim 10,further comprising: a first insulating sleeve; and a second insulatingsleeve, wherein the shell comprises a first opening and a secondopening, wherein the first insulating sleeve is disposed around thefirst opening, and wherein the second insulating sleeve is disposedaround the second opening.
 17. The separable insulated connector ofclaim 16, wherein the first insulating sleeve comprises rubber, andwherein the second insulating sleeve comprises rubber.
 18. The separableinsulated connector of claim 17, wherein the first insulating sleevecomprises ethylene propylene dienemonomer rubber, and wherein the secondinsulating sleeve comprises ethylene propylene dienemonomer rubber. 19.The separable insulated connector of claim 10, further comprising apulling eye.
 20. The separable insulated connector of claim 10, whereinthe conductive bus bar is in contact with the semi-conductive rubberhousing.
 21. A separable insulated connector, comprising: a shell; afaraday cage disposed within the shell; and a conductive bus barentirely disposed within the faraday cage, wherein the shell comprises afirst opening and a second opening, wherein the faraday cage comprises asemi-conductive rubber housing, the semi-conductive rubber housingcomprising a first cup and a second cup, wherein the first opening isaligned with the first cup, and wherein the second opening is alignedwith the second cup.
 22. The separable insulated connector of claim 21,wherein the conductive bus bar is in contact with the semi-conductiverubber housing.